MAKITA LH1040F User Manual

ECHNICAL INFORMATION  
PRODUCT  
P 1 / 20  
T
LH1040, LH1040F  
Models No.  
Description  
Table Top Miter Saw 260mm (10-1/4")  
CONCEPT AND MAIN APPLICATIONS  
Models LH1040 and LH1040F have been  
developed as multi-purpose miter saws.  
Installation of a table on Model LS1040  
has enabled miter saw and table saw to be  
H
Dimensions: mm (")  
packed in one tool for great versatility.  
LH1040F features LED built-in job light  
for accurate tracing of ink line in dark places.  
Length (L) 530 (20-7/8)  
Width (W) 476 (18-3/4)  
L
Height (H)  
535 (21)  
W
Specification  
Continuous Rating (W)  
Voltage (V)  
Cycle (Hz)  
Max. Output(W)  
Current (A)  
Input  
1,650  
1,650  
Output  
1,000  
1,000  
110  
120  
220  
230  
240  
15  
15  
50 / 60  
50 / 60  
50 / 60  
50 / 60  
50 / 60  
2,300  
2,300  
2,300  
2,300  
2,300  
7.9  
7.5  
7.2  
1,650  
1,650  
1,650  
1,000  
1,000  
1,000  
Model No.  
LH1040  
LH1040F  
No load speed: min-1 = rpm.  
4,800  
255 - 260 (10 - 10-1/4 )  
Diameter  
Saw blade: mm (")  
15.88 (5/8) 30.0 ( for European countries)  
Hole diameter  
Table saw  
Miter saw  
40 (1-9/16 )  
See the table below.  
Double insulation  
Yes  
Capacity: mm (")  
(with 260 mm saw)  
Protection against electric shock  
Electric brake  
LED job light  
No  
Yes  
Cord length: m (ft)  
2.5 ( 8.2 )  
Net weight: kg (lbs)  
13.7 (30.2 )  
Cutting capacity as Miter Saw  
Bevel angle  
Miter angle  
90  
°
45° Left bevel  
69mm x 130mm (2-3/4" x 5-1/8")  
93mm x 95mm (3-5/8" x 3-3/4")  
35mm x 130mm (1-3/8" x 5-1/8")  
53mm x 95mm (2-1/16" x 3-3/4")  
90  
°
69mm x 85mm (2-3/4" x 3-3/8")  
93mm x 67mm (3-5/8" x 2-5/8")  
35mm x 65mm (1-3/8" x 2-9/16")  
49mm x 42mm (1-15/16" x 1-5/8")  
45° Left  
69mm x 85mm (2-3/4" x 3-3/8")  
93mm x 67mm (3-5/8" x 2-5/8")  
35mm x 91mm (1-3/8" x 3-5/8")  
49mm x 67mm (1-15/16" x 2-5/8")  
45° Right  
Standard equipment  
Socket wrench 13 ....................... 1 pc  
Ring 16 (adaptor for saw blades  
with 25mm hole diameter) ......... 1 pc  
Triangular rule ............................ 1 pc  
Set plate ................................... 1 pc  
Blade cover .............................. 1 pc  
Push stick ................................. 1 pc  
Guide rule rule ........................ 1 pc  
TCT saw blade 260mm .......... 1 pc  
Dust bag ................................. 1 pc  
Holder set ............................... 1 pc  
Sub plate ass'y ........................ 1 pc  
Note: The standard equipment listed above may differ from country to country.  
Optional accessories  
Vertical vise  
Holder set  
Horizontal vise  
Assorted TCT saw blades  
P 3 / 20  
Repair  
[2] LUBRICATION  
Position  
No.  
Parts item  
Portion to be lubricated  
Hex bolt M10  
Rod 16  
Threaded portion  
124  
The surface where (127) Arm Complete contacts.  
The portion where (145) turn base contacts, when arm complete pivoting.  
Accepting portion for pivoting (1) Blade Case  
The groove to which O ring 5 is mounted.  
126  
127  
Arm complete  
129  
135  
145  
147  
150  
Stopper pin  
Slide plate  
The surface where (145) turn base contacts  
Accepting portion for pivoting (127) Arm Complete  
Accepting boss for the shaft of (145) Turn Base  
Both edge which contacts its accepting portion of (145) Turn Base  
Turn base  
Base complete  
Knock spring  
Tip of the threaded portion with which (150) Knock spring is pushed toward  
(145) Turn Base  
151  
A
Grip 32  
Thumb screw  
Tip of the threaded portion  
Fig.1-2  
O ring 5  
Accepting portion  
for (150) Knock Spring  
Rip fence  
P 4 / 20  
Repair  
< 3 > Removing table  
1. Lift up table by loosening two 54 levers which are equipped under the table. See Fig.2-1.  
2. Lift up the table to the highest level. See Fig.2-1.  
3. Remove pan head screw M5x16 and remove cover complete from riving knife. See Fig.2-2.  
4. Remove 8 M5x16 countersunk head screws. Then, table can be removed from blade case. See Fig.2-2.  
And remove compression spring 27 from blade case. See Fig.2-2.  
(In case of model LH1040 without fluorescent job light)  
4A. While lifting up the table, remove light circuit from the table. Then, table can be removed from blade case.  
And remove compression spring 27 from blade case. See Fig.2-2.  
(In case of model LH1040F with fluorescent job light)  
Fig.2-1  
Table  
Lever 54  
Fig.2-2  
Hex lock nut M5-8  
Pan head  
screw M5x16  
Cover complete  
Countersunk head  
screw M5x16 (8 pcs.)  
Table  
Riving knife  
Compression  
spring 21  
Table  
< 4 > Mounting table  
1. Secure table with 8 M5x16 countersunk head screws. Refer to Fig.2-2.  
2. While lifting up table to the highest level, mount compression spring 21 by inserting it from the side.  
3. Take the left step with referring to the above Figs.  
P 5 / 20  
Repair  
< 5 > Removing blade case section  
1. Remove living knife. See Fig.3-1.  
2. Remove lever 54, support plate and pipe 9-126. See Fig.3-1.  
The pipe 9-126 removed in this step, is used as a jig for removing rod 16 which functions as a pivot for blade case.  
3. Loosen lever 54 and press table support down to the surface of blade case. See Fig.3-2.  
Fig.3-1  
Fig.3-2  
Support plate  
Pipe 9-126  
Table support  
Living knife  
Hex flange  
head bolt M8x20  
Table support  
Lever 54  
Lever 54  
Rod 16  
4. Remove two M5x16 pan head screws. Now guard with guard holder can be removed from blade case. See Fig.3-3.  
5. Remove hex socket button head screw M6 (adhesive type), flat washer 7 and ring 7. Now the linkage of link plate with  
arm complete has been disconnected. See Fig.3-4.  
6. Remove stop ring E-5, flat washer 6 and ring 6. then, link plate can be removed from blade case. See Fig.3-5.  
Fig.3-3  
Fig.3-4  
Guard holder  
Blade case  
Arm complete  
Blade case  
Link plate  
Pan head  
screw M5x16  
Ring 7  
Guard  
Flat washer 7  
Hex socket button  
head screw M6  
Fig.3-5  
Stop ring E-5  
Flat washer 6  
Ring 6  
Link plate  
P 6 / 20  
Repair  
< 5 > Removing blade case section  
7. Lower the blade case section to the possible lowest position, and lock it at the same position with stopper pin.  
See Fig.3-6.  
8. While further pressing the blade case section, insert two screwdrivers into the side hole of blade case.  
See Fig.3-7. Or insert No.1R238 "Round Bar for Arbor" as illustrated in Fig.3-7A.  
9. Loosen hex socket head bolt M6x10 with hex wrench. See Fig.3-7.  
10. Apply pipe 9-126 on rod 16, and remove it by striking the pipe with plastic hammer toward the side of hex  
socket head bolt M6x10. See Fig.3-8. Now blade case section can be separated from arm complete.  
Fig.3-7  
Fig.3-6  
Hex wrench  
Screwdriver  
Hex socket  
head bolt M6x10  
Screwdriver  
Stopper pin  
Fig.3-8  
Fig.3-7A  
Hex wrench  
Hex socket  
head bolt M6x10  
Hex socket  
head bolt M6x10  
No.1R238  
Round Bar for Arbor  
Rod 16  
Pipe 9-126  
<Note>  
In order to minimize scratch on the accepting holes for rod 16, remove it toward  
the side of hex socket head bolt M6x10. See Fig.3-8A.  
Fig.3-8A  
Hex socket head bolt M6x10  
Blade  
case  
The portion scratched with  
hex socket head bolt M6x10  
Direction for  
removing rod 16  
Rod 16  
Arm complete  
The scratch on the accepting holes  
is minimized to this area.  
P 7 / 20  
Repair  
< 5 > Removing blade case section  
11. Put the removed blade case section on the turn base of arbor press, And set 1R306 "Ring Spring Removing Jig"  
between the two screwdrivers, inserted in the step of Fig.3-7. See Fig.3-9.  
12. Press down 1R306 "Ring Spring Removing Jig" with arbor press. So, spring holder is pressed down and  
the screwdrivers can be pulled out from blade case.  
Fig.3-9  
No.1R306  
Ring Spring Removing Jig  
Arbor press  
Screwdriver  
Blade case section  
13. Put the removed blade case section on the turn base of arbor press, And set 1R306 "Ring Spring Removing Jig"  
between the two screwdrivers, inserted in the step of Fig.3-7. See Fig.3-9.  
14. Press down 1R306 "Ring Spring Removing Jig" with arbor press in order to lower spring holder,  
while holding the blade case section firmly, so that it does not tilt or wobble.  
15. Slowly lessen the pressure to 1R306 "Ring Spring Removing Jig", while holding the blade case section  
firmly, so that it does not tilt or wobble. See Fig.3-10.  
16. Remove spring holder and compression spring 27 from blade case, when the jig gets free from the force  
of compression spring. See Fig.3-10.  
Fig.3-10  
No.1R306  
Ring Spring  
Removing Jig  
Slowly lessen the  
pressure to the jig.  
Spring holder  
Compression spring 27  
Blade case section  
P 8 / 20  
Repair  
< 5 > Mounting blade case section  
1. Take the reverse step of removing, while paying attention to the following matters.  
A. Scrape off the scratched portion of rod 16 with file, before mounting.  
Mount rod 16 from the side of hex socket head bolt M6x10 . See Fig.4-1.  
B. When pulling out two screwdrivers in the final step, press the blade case section down to the possible  
lowest position. Then, at the same time, spring holder is mounted to the original position automatically.  
C. Apply the adhesive to hex socket button head screw M6 with which link plate is secured to arm complete.  
Refer to Fig.3-4.  
Fig.4-1  
The portion scratched with  
hex socket head bolt M6x10,  
has to be scraped off, before  
mounting.  
Hex socket  
head bolt M6x10  
Direction for  
mounting rod 16  
Blade  
case  
Rod 16  
Arm complete  
< 6 > Disassembling safety cover section  
1. Loosen hex flange head bolt M8x12. Remove socket head flange screw M6 with hex wrench, inserted through  
the punched hole of safety cover. Now safety cover section can be separated from blade case. See Fig.5-1.  
2. The safety cover section can be disassembled by unscrewing pan head screw M5x12. See Fig.5-2.  
Fig.5-1  
Fig.5-2  
Center cover  
Blade case section  
Center plate  
Torsion spring 36  
Safety cover  
Flat washer 5  
Pan head  
screw M5x12  
Socket head  
flange screw M6  
Hex flange head  
bolt M8x12  
Tapping screw  
bind PT3x8  
Safety cover  
Hex wrench  
No need to remove socket head flange screw M6  
from center cover, for easy reassembling.  
< 7 > Assembling safety cover section  
1. In case of the disassembling as illustrated in Fig.5-2, tapping screw bind PT3x8 has to be  
removed from safety cover before reassembling.  
2. Drive tapping screw bind PT3x8 again, after mounting torsion spring 36, center cover and center plate.  
Refer to Fig.5-2.  
P 9 / 20  
Repair  
< 8 > Disassembling motor section  
1. Remove carbon brush. See FIg.6-1.  
And then, remove table from blade case section as illustrated in Fig.2-1 and Fig.2-2.  
2. Remove lever 54 and support plate. See Fig.6-2.  
3. After removing four M6x60 pan head screws, motor section can be separated from blade case. See Fig.6-3.  
<Note>  
Compression spring 9 for shaft lock falls off easily from the machine, when separating motor section  
from blade case. Be careful, not to lose this spring.  
Fig.6-2  
Support plate  
Fig.6-1  
Carbon brush  
Brush  
holder cap  
Lver 54  
Brush holder cap  
Carbon brush  
Fig.6-3  
Pan head screw M6x60  
Shaft lock  
Pan head  
screw M6x60  
Compression spring 9  
< 9 > Assembling motor section  
1. Putting shaft lock into the notch of motor housing, mount armature to motor housing. See Fig.7-1.  
2. While pushing shaft lock to the direction designated with black arrow, mount the motor section  
to blade case in order to avoide piching of shaft lock between motor housing and blade case. See Fig.7-2.  
3. Take the reverse step of disassembling after the above process.  
Fig.7-1  
Fig.7-2  
Notch for shaft lock slide  
Armature  
Shaft lock  
Shaft lock  
Compression spring 9  
P 10 / 20  
Repair  
< 10> Disassembling safety block mechanism  
1. Lock the blade case section at the possible highest position, with stopper pin.  
2. Remove lock lever by unscrewing 2 M4x10 pan head screws. Then, lock lever can be removed from lock pin.  
See Fig.8-1.  
3. Remove motor section as shown in <8> Disassembling motor section, when removing lock pin 8. See Fig.8-2.  
Fig.8-1  
Fig.8-2  
Lock pin 8  
Lock pin 8  
Torsion spring 9  
Pan head screw M4x10  
Lock lever  
<11> Assembling safety block mechanism  
1. Pass lock pin 8 through torsion spring 9, and hold its tail with switch box. See Fig.9-1.  
2. While sliding lock lever to switch button side, tighten lock lever with one M4x10 pan head screw preliminarily.  
See Fig.9-2.  
3. Nip the hooked tail of torsion spring 9 and put it on lock lever. See Fig.9-3.  
Switch box  
Fig.9-2  
Fig.9-1  
Lock pin 8  
Slide lock lever to  
switch button side,  
when preliminary  
tightening.  
Switch box  
Switch box  
Hold this side  
with switch box.  
Switch button  
Preliminary tightening  
with one M4x10 pan  
head screw  
Torsion spring 9  
Fig.9-3  
Torsion spring 9  
Switch box  
Lock pin 8  
Hooked tail of torsion  
spring 9, put on lock lever  
Lock lever  
P 11 / 20  
Repair  
<11> Assembling safety block mechanism  
4. Adjust the position of lock lever so that the distance between lock lever and safety cover is approx. 1mm.  
See Fig.9-4. And then, finally tighten lock lever with 2 Mx10 pan head screws.  
Fig.9-4  
Lock lever  
Safety cover  
Approx. 1mm  
<12> Removing turn base  
1. Remove grip 32. From the bottom side of base, unscrew pan head screw M5x12. Now knock spring can be removed.  
See Fig.10-1.  
2. After removing guide fence, lever up kerf board with screwdriver to remove them. See Fig.10-2.  
3. Remove hex lock nut M8x13 and flat washer 8. Now turn base can be removed from base. See Fig.10-3.  
Fig.10-1  
Fig.10-2  
Hex bolt M8x30  
Guide fence  
Hex bolt M8x30  
Kerf board  
Grip 32  
Knock spring  
Turn base  
Pan head screw M5x12  
Screwdriver  
P 12 / 20  
Repair  
<12> Removing turn base  
3. Remove hex lock nut M8x13 and flat washer 8. Now turn base can be removed from base. See Fig.10-3.  
Fig.10-3  
Hex lock nut M8x13  
Socket wrench 13  
which comes  
with the product.  
Turn base  
Flat washer 8  
Base  
<13> Mounting turn base  
1. Mount turn base and flat washer 8, and tighten hex lock nut M8x13 with socket wrench 13.  
The hex lock nut M8x13 has to be so tightened, that turn base can move without wobbling.  
2 Take the reverse step of disassembling after the above process.  
<14> Angle adjustment of saw blade  
1. Adjusting to 90 to turn base,  
°
While applying 1R208 "90-degree Set Square", turn Hex bolt M8x28 of motor housing side,  
until both saw blade and turn base contact the jig closely. See Fig.11-1.  
2. Adjusting to 45 to turn base,  
°
While applying 1R207 "45-degree Set Square", turn Hex bolt M8x28 of saw blade side,  
until both saw blade and turn base contact the jig closely. See Fig.11-2.  
Fig.11-2  
Fig.11-1  
Hex bolt M8x28  
of motor housing side  
1R209  
45-degree Set Square  
Turn base  
Turn base  
1R208  
Hex bolt M8x28  
of saw blade side  
90-degree Set Square  
P 13 / 20  
Repair  
<15> Squaring adjustment of guide fence  
1. Set the bevel angle 90°.  
2. Provisionally tighten M8x30 hex bolt (B) into the smaller screw hole on the left side of guide fence  
when viewed from operator's position.  
3. While checking the angle of guide rule to saw blade using 90 Degrees set square (No.1R208), pivot the guide fence  
by moving its right end until the angle is 90 degrees  
.
4. After completion of squaring adjustment, securely tighten four M8x30 hex bolts; first A and D, then B and C.  
Fig.12-1  
Screw hole smaller  
than the other 3 screw holes.  
Hex bolt M8x30  
Hex bolt M8x30  
D
C
A
B
Guide fence  
When adjusting,  
move this side.  
90 Degrees set square  
(No.1R208)  
Saw blade  
Operator's position  
<16> Repairing switch section  
Handle cover can not be separated from switch box without removing lock lever of safety lock mechanism.  
Remove lock lever as illustrated in Fig.8-1.  
1. Remove handle cover, Now relay can be replaced. See Fig.13-1.  
Fig.13-1  
Handle cover  
Relay  
Switch box  
2. Do not forget to mount clamp plate and felt ring 6, when assembling switch section. And do not remove sponge  
sheet from handle cover, when mounting it to switch box. Because these three parts protect the machine  
against saw dust. See Fig.13-2.  
Fig.13-2  
Motor housing  
Handle cover  
Switch box  
Felt rig 6  
Pin  
Sponge sheet  
Pin  
Clamp plate  
Switch button OFF  
Switch button ON  
P 14 / 20  
Circuit diagram  
(1) LH1040F with fluorescent job light for  
* High voltage area in Europe,  
* High voltage area in Saudi Arabia  
* Cyprus  
* Kuwait  
* Bhutan  
Color index of lead wires' sheath  
Blue  
Black  
White  
Red  
Yellow  
Orange  
Purple  
Brown  
Gray  
Light switch box  
Switch for light  
Light circuit  
Varnish tetron  
tube  
41 31  
1
3
A1  
Terminal  
block  
42 32  
2
4
A2  
Sponge  
**Noise suppressor  
Circuit for  
soft start  
*Main switch  
(Relay)  
Power supply  
cord  
Brush holder  
(Turn base side)  
Switch box  
Brush holder  
(Table side)  
*Main switch  
(Relay): Its terminal No. 31, 3, 42,  
Motor housing  
2 and A2 are equipped with  
receptacle sleeves.  
**Noise suppressor: The product is supplied without equipping  
noise suppressor for some countries.  
P 15 / 20  
Circuit diagram  
(2) LH1040F with fluorescent job light  
for Low voltage in Great Britain  
Color index of lead wires' sheath  
Blue  
Black  
White  
Red  
Purple  
Brown  
Yellow  
Orange  
Noise suppressor  
Light switch box  
Switch for light  
Light circuit  
Line filter  
Varnish tetron  
tube  
41  
1
3
5
A1  
Terminal  
block  
42  
2
4
6
A2  
*Main switch  
(Relay)  
Sponge  
Circuit for  
soft start  
Power supply  
cord  
*Main switch  
(Relay): Its terminal No. 42, 4, 5  
and A2 are equipped with  
receptacle sleeves.  
Brush holder  
(Turn base side)  
Switch box  
Brush holder  
(Table side)  
Motor housing  
P 16 / 20  
Circuit diagram  
(1) LH1040 without fluorescent job light, for  
* High voltage area in Europe,  
* High voltage area in Saudi Arabia  
* Cyprus  
* Kuwait  
* Bhutan  
Color index of lead wires' sheath  
Black  
Orange  
White  
Red  
Purple  
Gray  
Yellow  
Varnish tetron  
tube  
41 31  
1
3
A1  
Terminal  
block  
*Main switch  
(Relay)  
42 32  
2
4
A2  
**Noise suppressor  
Sponge  
Circuit for  
soft start  
Power supply  
cord  
Brush holder  
(Turn base side)  
Switch box  
Brush holder  
(Table side)  
Motor housing  
*Main switch  
(Relay): Its terminal No. 31, 3, 42,  
2 and A2 are equipped with  
receptacle sleeves.  
**Noise suppressor: The product is supplied without equipping  
noise suppressor for some countries.  
P 17 / 20  
Circuit diagram  
(2) LH1040 without fluorescent job light  
for Low voltage in Great Britain  
Color index of lead wires' sheath  
Black  
White  
Blue  
Purple  
Red  
Orange  
Brown  
Yellow  
Noise suppressor  
Line filter  
Varnish tetron  
tube  
41  
1
3
5
A1  
Terminal  
block  
42  
2
4
6
A2  
*Main switch  
(Relay)  
Sponge  
Circuit for  
soft start  
Power supply  
cord  
*Main switch  
(Relay): Its terminal No. 42, 4, 5  
and A2 are equipped with  
receptacle sleeves.  
Brush holder  
(Turn base side)  
Switch box  
Brush holder  
(Table side)  
Motor housing  
P 18 /20  
Wiring diagram  
under Housing Cover  
Terminal block  
Insulated connector  
Motor housing  
Housing cover  
Lead wire of  
soft start circuit  
Punched hole  
Do not push insulated connector  
into motor housing through the  
punched hole.  
Lead holder  
Soft start circuit  
Lead wire of soft start  
circuit has to be held  
with the lead holder.  
Varnish tetron  
tube  
Motor housing  
The lead wires which are put  
on the edge of field, have to  
be bundled with varnish tetron  
tubes by separating in two groups.  
And max. four lead wires have to  
be in each bundle.  
Rib  
Field  
Varnish tetron  
tube  
P 19 /20  
Wiring diagram  
Under clamp plate  
Clamp plate  
Rib A  
Field lead wire  
(orange)  
Before securing clamp plate,  
put the lead wires  
between rib A and B.  
Soft start lead wire  
(Purple)  
Rib B  
Put line filter in the space illustrated  
above. (exclusively for low voltage  
in Great Britain)  
Line filter  
When line filter is used, pass the following  
lead wires through line filter.  
* Field lead wire  
(orange)  
* Soft start lead wire  
(Purple)  
Field lead wire  
(orange)  
Soft start lead wire  
(Purple)  
In switch box  
Put the insulated connectors into  
the space between relay and inner wall,  
or  
push into the punched hole.  
Be careful, not to pinch the lead wires of light circuit  
between rib B and relay, when fluorescent job light is installed.  
When putting lead wires onto relay,  
Hole for  
pipe 9-126  
Rib B  
do not put them on this area.  
Switch button  
Relay  
Inner wall  
Rib A  
Punched hole  
for lead wires  
Noise suppressor  
Put noise suppressor  
into the space between  
relay and inner wall,  
or  
push it into the punched  
hole, when it is used.  
Boss  
Put the lead wires, connected to relay  
through punched hole, between boss  
and rib A.  
P 20 / 20  
Wiring diagram  
Light Switch Box  
Cord of light circuit  
Light switch box  
Switch for light circuit  
Put lead wires in  
the lead holder.  
Lead holder  
Insulated connector  
Put insulated terminal in  
the space shown in the  
above illustration.  

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